QFR No - 7001067878
Defect Details
| NC No. | 7001067878 |
| NC Date | 25/10/2024 |
| NC Submission Date | |
| Part No. | F1DZ00902B |
| Part Name | FORK BOLT K86A |
| Supplier Name & Code | 100106-SHARP ENGINEERS. |
| ETL Plant | 1136-ETL Suspension Sanand |
| Defect Details | MATERIAL DEFECT-Pitting mark |
1. Problem Description
| Defect Description | Pitting marks (Material defect) |
| Detection Stage | Receipt |
| Problem Severity | Aesthetic |
| NG Quantity | 1870 |
| Is Defect Repeatative? | No |
| Defect Sketch / Photo |
Supplier Communication Details
| Quality Head Email ID | quality@apw3.co.in |
| Plant Head/CEO Email ID | kurund.ma@sharp-engineers.com |
| MD Email ID | urkhandelwal@sharp-engineers.com |
2. Stock Details & action taken for NG parts
| Location | ETL End | Warehouse | Transit | Supplier FG | Supplier WIP | Total |
|---|---|---|---|---|---|---|
| Total Qty |
2600
|
0
|
0
|
1500
|
0
|
4100
|
| Check Qty |
2600
|
0
|
0
|
1500
|
0
|
4100
|
| NG Qty |
1870
|
0
|
0
|
1400
|
0
|
3270
|
| Scrap | 0 |
| Rework | 3270 |
| Under Deviation | 0 |
| Containment Action |
|---|
| All pipeline material segregated |
3. Process Flow
| Process Flow Description |
|---|
| RM inward-Paring and drilling-CNC setup-OD grinding-Milling-Roliing-Plating-FID-Packing and forwarding |
4. Process Details
| Process / Operation | RM inwarding |
| Outsource | Yes |
| Machine / Cell | RM supplier |
| Machine / Cell No. | RM supplier |
5. Problem Analysis
| Type | Possible Cause | Fact Verification | Jud |
|---|---|---|---|
| Material | Material changed | Material found as per specification | O |
| Man | manpower changed | manpower deployed as per skill matrix | O |
| Machine | Operation missing | OD turning operation not done | X |
| Method | part not clamp properly | part clamp properly | O |
| Tool | Tool Change | no tool change | O |
6. Inspection Method Analysis (Current)
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | Sampling |
| Sampling | No |
| Sample Size | 5 nos |
7. Root Cause Analysis (Occurance)
| Why 1 | Pitting Mark |
| Why 2 | Pitting Mark at OD Collar |
| Why 3 | OD turning Operation not done |
| Why 4 | OD turning operation not available in program |
| Why 5 | |
| Root Cause (Occurance) | OD turning operation not available in program |
Root Cause Analysis (Outflow)
| Why 1 | Pitting Mark |
| Why 2 | Skip From inspection |
| Why 3 | Inspector not aware about defect |
| Why 4 | |
| Why 5 | |
| Root Cause (Outflow) | Inspector not aware about defect |
8. Countermeasure ( Occurrence , Outflow & System side Actions )
| Type | Countermeasure Details | Responsibility | Target Date | Actual Date | Status |
|---|---|---|---|---|---|
| Outflow | Onjob Training given to inspector | Mr. Omkar Bhange | 28/10/2024 | 28/10/2024 | Completed |
| Occurance | 1)OD turning Operation added in CNC program 2) RM Size increase by 0.05mm | Mr. Manoj Kadam | 28/10/2024 | 28/10/2024 | Completed |
| Outflow | OPL displayed st final and machine stage | Omkar Bhange | 26/10/2024 | 26/10/2024 | Completed |
9. Inspection Method After Customer Complaint
| Change In Inspection System | Yes |
| Change Details | Started 100% inspection at final inspection |
| Inspection Method | Other |
| Other Inspection Method | Visual |
| Check Point at Final Inspection | Yes |
| Checking Freq. | 100% |
| Sampling | No |
| Sample Size | 100 |
10. Evidance of Countermeasure
| Occurance (Before) |
RM of OD 29.50 +0.1 mm were used for fork bolt K-86 1189_Occurance_Before.pdf |
| Occurance (After) |
Now, RM of OD 29.55 +0.1 mm are using for fork bolt K-86 1189_Occurance_After.pdf |
| Outflow (Before) |
Inspector were not aware about defect 1189_Outflow_Before.png |
| Outflow (After) |
On job training given to the inspector 1189_Outflow_After.pdf |
11. Horizontal Deployment
| Horizontal Deployment Required | Yes |
| Applicable Machine / Model / Plant | All fork bolt |
12. Document Review
| Documents | InspCheckSheet |
| Specify Other Document | NA |
13. Effectiveness Of Action
| Reviewed Quantity | 5 |
| Reason for submission | Material defect -Pitting mark |